System and method for manufacturing downhole tool components

ABSTRACT

A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.

This application is a continuation of U.S. application Ser. No.15/520,775, filed Apr. 20, 2017, which is the national stage entry ofPCT/US2014/067142 filed Nov. 24, 2014, each of the aforementionedapplications are expressly incorporated herein in its entirety.

FIELD

The present disclosure relates generally to drilling systems andparticularly to drilling systems used for oil and gas exploration andproduction operations. More specifically, the present disclosuredescribes techniques for manufacturing downhole tool components usingincremental construction techniques and subtractive manufacturingtechniques.

BACKGROUND

A drill string is used in oil and gas exploration and production toreach subterranean destinations or formations. A drill string isassembled during drilling operations by joining tubular sections thatinclude drill pipe, transition pipe, and a bottom hole assembly (“BHA”).An individual section of drill pipe may be referred to in the art as ajoint. A pre-assembled group of two or more joints may be referred to inthe art as a stand. As the well is drilled, joints or stands are addedto the drill string from the surface until the desired depth is reached.The BHA typically includes a drill bit, drill collars, and drillingstabilizers. The drill collars may include downhole tools. The drillpipe and drill collars may be joined together using threadedconnections. Subs may be used to connect sections with dissimilarthreads.

The drill collars may be approximately 6-10 feet (1.8 m-3 m) in lengthand may include tools such as a downhole motor, a rotary steerable ordirectional drilling system, measurement while drilling (“MWD”)equipment, logging while drilling (“LWD”) equipment, and telemetrysystems. A joint is typically on the order of 30 feet (9.1 m) long andhas a small diameter and a relatively long length such as a depth tobore diameter ratio greater than 10:1. For example, each joint mayinclude a diameter ranging from 1.5 to 5 inches and a length of 30 feet.

The components or modules within a drill string may include complexinternal bore features that form conduits for routing wires or directingfluids through the drill string. The bore features may be formedparallel to, at an angle to, and/or perpendicular to a center linepassing axially through the drill string.

Existing manufacturing techniques employ sophisticated equipment such as“gun drilling” to bore long and narrow passages axially through thesections. Existing manufacturing techniques must meet particular angletolerances, profile tolerances, or positional tolerances to preciselyform conduits or passages through the sections. As a result, partiallycompleted portions of sections may need to be discarded andre-manufactured due to design tolerance faults.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the present technology will now be described, by wayof example only, with reference to the attached figures, wherein:

FIG. 1A is a partial cross-sectional view illustrating an embodiment ofa drilling rig for drilling a wellbore with the drilling systemconfigured in accordance with the principles of the present disclosure;

FIG. 1B is a perspective cross-sectional view illustrating a drill pipeencasing a segment constructed from a plurality of layers according tothe present disclosure;

FIG. 2 is a perspective view of one embodiment of a single layer thatcorresponds to the segment illustrated in FIG. 5, according to thepresent disclosure;

FIG. 3 is a perspective view of one embodiment corresponding to afixture used to form a segment, according to the present disclosure;

FIG. 4 is a perspective view of one embodiment corresponding to afixture having a segment mounted thereon, the segment being constructedfrom a plurality of layers, according to the present disclosure;

FIG. 5 is a perspective view of one embodiment of a segment constructedfrom a plurality of fused layers, the segment includes a long and narrowbore feature according to the present disclosure;

FIG. 6 is a perspective view of another embodiment of a single layerthat corresponds to the segment illustrated in FIG. 9, according to thepresent disclosure;

FIG. 7 is a perspective view of another embodiment corresponding to afixture used to form a segment, according to the present disclosure;

FIG. 8 is a perspective view of another embodiment corresponding to afixture having a segment mounted thereon, the segment being constructedfrom a plurality of layers, according to the present disclosure;

FIG. 9 is a perspective view of one embodiment of a segment constructedfrom a plurality of fused layers, the segment includes a long and narrowbore feature according to the present disclosure;

FIG. 10 is a flowchart of an example method according to the presentdisclosure.

DETAILED DESCRIPTION

It will be appreciated that for simplicity and clarity of illustration,where appropriate, reference numerals have been repeated among thedifferent figures to indicate corresponding or analogous elements. Inaddition, numerous specific details are set forth in order to provide athorough understanding of the embodiments described herein. However, itwill be understood by those of ordinary skill in the art that theembodiments described herein can be practiced without these specificdetails. In other instances, methods, procedures and components have notbeen described in detail so as not to obscure the related relevantfeature being described. Also, the description is not to be consideredas limiting the scope of the embodiments described herein. The drawingsare not necessarily to scale and the proportions of certain parts havebeen exaggerated to better illustrate details and features of thepresent disclosure.

In the following description, terms such as “upper,” “upward,” “lower,”“downward,” “above,” “below,” “downhole,” “uphole,” “longitudinal,”“lateral,” and the like, as used herein, shall mean in relation to thebottom or furthest extent of, the surrounding wellbore even though thewellbore or portions of it may be deviated or horizontal.Correspondingly, the transverse, axial, lateral, longitudinal, radial,and the like orientations shall mean positions relative to theorientation of the wellbore or tool. Additionally, the illustratedembodiments are depicted so that the orientation is such that theright-hand side is downhole compared to the left-hand side.

Several definitions that apply throughout this disclosure will now bepresented. The term “coupled” is defined as connected, whether directlyor indirectly through intervening components, and is not necessarilylimited to physical connections. The connection can be such that theobjects are permanently connected or releasably connected. The term“communicatively coupled” is defined as connected, either directly orindirectly through intervening components, and the connections are notnecessarily limited to physical connections, but are connections thataccommodate the transfer of data, fluids, or other matter between theso-described components. The term “outside” refers to a region that isbeyond the outermost confines of a physical object. The term “inside”indicates that at least a portion of a region is partially containedwithin a boundary formed by the object. The term “substantially” isdefined to be essentially conforming to the particular dimension, shapeor other thing that “substantially” modifies, such that the componentneed not be exact. For example, substantially cylindrical means that theobject resembles a cylinder, but can have one or more deviations from atrue cylinder. The terms “comprising,” “including” and “having” are usedinterchangeably in this disclosure. The terms “comprising,” “including”and “having” mean to include, but not necessarily be limited to thethings so described.

The term “radial” and/or “radially” means substantially in a directionalong a radius of the object, or having a directional component in adirection along a radius of the object, even if the object is notexactly circular or cylindrical. The term “axially” means substantiallyalong a direction of the axis of the object. If not specified, the termaxially is such that it refers to the longer axis of the object.

The drill string described in any of the various embodiments maycomprise various equipment defining a fluid conduit, that extendsdownhole to support drilling operations. The drill string may include,for example, drill pipe, transition pipe, and a BHA having a drill bit,drill collars, and drilling stabilizers. The drill string may includedrill pipe formed from individual joints, continuous coil tubing, or anyother conduit that extends downhole to support drilling or workoveroperations. Each drill string used on a particular job or site isgenerally unique since its tools are selected based on factorsparticular to the well or the site, such as geology (e.g. composition ofthe formation including rock type, density, abrasiveness, etc.),budgetary and other considerations limiting which equipment isappropriate, and other factors with which one of ordinary skill in theart is familiar. An individual section of drill pipe may be referred toin the art as a joint.

“Processor” as used herein is an electronic circuit that can makedeterminations based upon inputs and is interchangeable with the term“controller.” A processor can include a microprocessor, amicrocontroller, and a central processing unit, among others. While asingle processor can be used, the present disclosure can be implementedover a plurality of processors, including local controllers provided ina tool or sensors provided along the drill pipe.

According to one example, open-hole operations are employed during wellconstruction. The open-hole operations typically include forming casingstrings, such as a surface casing and intermediate casing. If a well isdetermined to be viable, then well completion may include forming aproduction casing for cased-hole operations.

Because a drill string can contain any of a variety of tubularcomponents and other equipment custom-selected for a particular job orsite, the term “segment” is used generally throughout this disclosure torefer to any part of the drill string. For example, a segment may referto downhole oilfield tools including a downhole motor, components of arotary steerable or directional drilling system, components ofmeasurement while drilling (“MWD”) equipment, components of loggingwhile drilling (“LWD”) equipment, and components of telemetry systems. Aparticular segments may have a small diameter and a relatively longlength such as, for example, a depth to bore diameter ratio greater than10:1. According to one example, segments or components thereof mayinclude a substantially cylindrical external shape and may includecomplex internal features and shapes. The internal features may beoriented parallel to, perpendicular to, or at an angle to a center linepassing axially through the segment. One of ordinary skill in the artwill readily appreciate that internal and external features of segmentsmay be provided in any shape.

This disclosure describes novel systems and methods of designing andmanufacturing segments for drill string in order to reduce machiningcosts and manufacturing complexity. This disclosure describes producingsegments from a plurality of slices or layers. According to one example,the layers may be sliced in a direction perpendicular to an axialdirection of the segment. During the manufacturing process, theplurality of layers are arranged in a preselected order and may beexposed to a welding process that fuses the plurality of layers togetherto form a solid segment as described in greater detail below. Themanufacturing process may be performed in a standard environment, suchas a factory, warehouse, or the like. In other words, the manufacturingprocess does not require vacuum conditions, temperature control, or thelike.

This disclosure provides a system and method of manufacturing segmentsusing incremental construction techniques such as layer manufacturingthat allows for incremental monitoring of design tolerances duringproduction. Furthermore, this disclosure provides a system and method ofre-manufacturing portions of partially assembled segments duringproduction. According to one example, segments include long parts withcomplex internal features. For example, the internal features mayinclude long and narrow bores that form a narrow wireway to direct andpass wires or the like. Alternatively or additionally, the internalfeatures may include long and narrow bores that form a narrow hydraulicpassage to direct and pass hydraulic fluids, borehole fluids, formationfluids, or the like. Alternatively or additionally, the internalfeatures may include cavities that receive components such as controlvalves, connectors, gauges, sensors, or the like. One of ordinary skillin the art will readily appreciate that other internal features may beprovided in the drill string.

FIG. 1A is a partial cross-sectional view of a drilling rig for drillinga wellbore with the drilling system 100. The drilling system 100 employsa drill string 112 with downhole tools described herein to form asubterranean well according to one example. The subterranean well isillustrated with a wellbore 102 drilled into the earth 104 from theground's surface 106 using a drill bit 110 provided on the drill string112. For illustrative purposes, the top portion of the wellbore 102includes a surface casing 107 that defines and stabilizes the wellbore102 after being drilled, which is cemented in place. The wellbore 102also may include intermediate casings (not shown), which may bestabilized with cement. The casing 107 performs several functions,including preventing wellbore collapse, maintaining a physicalseparation between the Earth's layers, providing a barrier to preventfluid migration, enhancing safety, and protecting the Earth's layersfrom any contaminants, or the like.

The drill bit 110 is located at the bottom, distal end of the drillstring 112. During drilling operations, the drill string 112 with theincluded BHA with drill bit 110 are advanced into the earth 104 by adrilling rig 120, typically by rotating the drill string 112 from thesurface. The drilling rig 120 may be supported directly on land asillustrated or on an intermediate platform if at sea.

The wellbore 102, which is illustrated extending downhole into theEarth's layers, and any components inside the wellbore 102 are subjectedto hydrostatic pressure originating from subterranean destinations orformations.

The lower end portion of the drill string 112 may include a drill collarprovided proximate to the drilling bit 110. The drill bit 110 may be aroller cone bit, a fixed cutter bit, or any other type of bit known inthe art. For purposes of completeness, FIG. 1A illustrates that thedisclosure supports coiled tubing 150 and wireline 152 deployment, whichare contemplated and within the context of this disclosure.

FIG. 1B is a perspective cross-sectional view of a section of drillstring 112 that encases a segment 180 constructed from a plurality offused layers 181 a-181 n as described in greater detail below. While thedrill string 112 and the segment 180 are illustrated as being in directcontact, one of ordinary skill in the art will readily appreciate thatintermediate components may be provided between the drill string 112 andthe segment 180. For example, seals, bearings, wear sleeves, and otherintermediate components may be provided between the drill string 112 andthe segment 180.

FIG. 2 is a perspective view of a single layer 200 that when fused withother single layers 200 produces a segment 180 having fused layers 181a-181 n, such as illustrated by way of example in FIG. 5. According toone example, the single layer 200 may include a large aperture 202 and asmall aperture 204. While the single layer 200 is illustrated to includeapertures 202, 204, one of ordinary skill in the art will readilyappreciate that the single layer 200 may include any number ofapertures, any size of apertures, any shape of aperture, to meet desireddesign goals.

According to one example, the single layer 200 may be formed using knownmachining techniques such as turning, milling, forging, electricdischarge machining (“EDM”), among other subtractive manufacturingtechniques. For example, the single layer 200 may be formed usingsheet-metal forming or stamping processes. Upon creating the singlelayer 200, additional subtractive manufacturing techniques may be usedto define features within the single layer 200. One of ordinary skill inthe art will readily appreciate that selection of the appropriatetechnique for forming and creating the single layer 200 may be based onfactors such as a desired thickness of the single layer 200, desireddimensions of the single layer 200, desired dimensions of featureswithin the single layer 200, and desired tolerances of dimensions, orthe like.

With further reference to FIG. 2, the various surfaces 205, 207, 209,211 of the single layer 200 are exposed to the atmosphere before beingfused into the segment 180 having fused layers 181 a-181 n. Accordingly,these various surfaces 205, 207, 209, 211 may be easily accessed priorto being fused into the segment 180. For example, these various surfaces205, 207, 209, 211 may be accessed using conventional sprayingtechniques and may be spray coated for protection from harmful contactwith heat, corrosive fluids, or the like. Spray coating these surfacesmay provide beneficial qualities such as increased wear resistance,increased corrosion resistance, or the like. Additionally, the singlelayer 200 may be quickly inspected prior to being fused in order toconfirm that a desired treatment was performed. By contrast,conventional segments that are machined from material having a depth tobore diameter ratio greater than 10:1 are dimensioned to requirespecialized equipment to access interior features of the segment.Assuming specialized equipment is available to perform desiredoperations, any desired inspections will also require specializedequipment. Accordingly, the single layer construction described hereinprovides advantages over existing techniques that use material having adepth to bore diameter ratio greater than 10:1 to manufacture downholetool components.

Another advantage of assembling a segment 180 from a plurality of singlefused layers 181 as described herein is that components such as sensors,antennas, and electrical wiring may be embedded within any portion of apartially assembled segment 180 during fabrication. Accordingly,component placement constraints within the segment 180 are eased sincecomponents may be spread throughout the entire volume of the segment 180during fabrication. Thus, component separation distances within the toolor segment 180 may be increased in order to reduce componentinterference. Furthermore, the manufacturing techniques described hereinallow component stacking along the axial direction during fabrication.By contrast, existing manufacturing techniques limit component placementto peripheral areas of segments that are easily reached afterfabrication using subtractive manufacturing techniques. Thus, existingmanufacturing techniques provide higher density configurations bylimiting component placement after fabrication to areas that areproximate to the surface of the segment.

Returning to FIG. 1A, sensor sub-units 130, 132 are shown within thecased portion of the well and may be embedded into correspondingsegments 180 using the techniques described herein. Sensor sub-units130, 132 may be components of MWD and LWD tools that are enabled tosense nearby characteristics and conditions of the drill string,formation fluid, casing, and surrounding formation, or the like. Datacorresponding to the sensed conditions and characteristics may berecorded downhole for later download such as at a processor (not shown)that may be embedded into a corresponding segment 180 using thetechniques described herein. Alternatively, the data may be communicatedto the surface either by wire using repeaters 134,136 up to surface wire138, or wirelessly using components embedded into corresponding segment180 using the techniques described herein. If wirelessly, the downholetransceiver (antenna) 134 may be utilized to send data to a localprocessor 140, via surface transceiver (antenna) 142. These componentsmay be embedded into corresponding segments 180 using the techniquesdescribed herein. The data may be either processed at the processor 140or further transmitted along to a remote processor 144 via wire 146 orwirelessly via antennae 142 and 148. A surface installation 170 may beprovided to send and receive data to and from the well via repeaters134,136. The data may include well conditions such as formationhydrostatic pressure, backpressure hydrostatic pressure, well depth,temperatures, or the like.

With respect to serviceability of components that are embeddedthroughout the entire volume of the segment 180, these lower densitysegments 180 may be manufactured for replacement rather than repair. Inother words, any segments 180 having axially stacked components toprovide lower component density may be manufactured for replacementrather than repair. For example, these segments 180 may be of a smallersize and may be positioned for easy access and removal from the drillstring. Furthermore, if these segments 180 with axially stackedcomponents are produced at lower cost with improved reliability, thenthese segments 180 may be replaced on a pre-determined schedule prior tofailure. Still further, these segments 180 may be sent to a recyclingfacility and selected portions may be incorporated into new segmentsduring the assembly process described herein.

According to another example, the components may be embedded into thesegment 180 when a cavity designed to hold a corresponding component issubstantially complete to support the component. Accordingly, thecomponent may be inspected and tested during construction to improvequality control, for example. By contrast, existing techniques do notsupport embedding components into a segment during assembly. Forexample, existing techniques that employ additive manufacturing toconstruct segments using a plurality of single layers do not enableinspection and testing of components during construction. Typically,existing systems require subtractive manufacturing techniques such asdrilling to access pre-formed cavities designed to hold components. Asdiscussed above, existing manufacturing techniques limit componentplacement to areas that are reachable after fabrication usingsubtractive manufacturing techniques. Furthermore, compared to thedisclosure herein, existing systems require additional steps for placingcomponents in pre-formed cavities.

FIG. 3 is a perspective view of a fixture 300 that may be used toassemble the segment from a plurality of single unfused layers 200illustrated in FIG. 2. The fixture 300 includes a base 302 that supportsalignment features such as a large rod 304 and a small rod 306. Thelarge rod 304 may be dimensioned to correspond to aperture 202. Thesmall rod 306 may be dimensioned to correspond to aperture 204.Additionally, the large rod 304 and the small rod 306 may be oriented onthe base 302 to align with a relative positioning of apertures 202, 204on the single layer 200.

According to one example, a tube or insert may be provided to fit overthe large rod 304 and/or the small rod 306. For example, if theapertures 204 from a plurality of single unfused layers 200 are providedto form a fluid passage such as hydraulic passageway, then a solid tube310 may be inserted over the small rod 306 to provide a continuouslining on the inside of the apertures 204. In this case, the apertures204 may be machined with a circumference that fits over the outerdiameter of the tube 310. The tube 310 may be secured within thepassageway using a press fit. Alternatively, the tube 310 may be securedwithin the passageway by welding. In operation, the tube 310 may preventfluid from leaking out of the fluid passage if any of the single fusedlayers 181 do not form a fluid tight passage. For example, the singlefused layers 181 may not form a fluid tight passage if a weldingoperation is not performed in close proximity to a narrow bore formed bythe apertures 204. According to one example, the welding operation maynot be performed proximate to the apertures 204 in order to avoiddeformation of the apertures 204.

FIG. 4 is a perspective view of the fixture 300 with the plurality ofunfused single layers 200 a-200 n (hereinafter 200) mounted thereon. Asshown, the large rod 304 is received by the apertures 202 of theplurality of unfused single layers 200 and the small rod 306 is receivedby the apertures 204 of the plurality of unfused single layers 200.According to one example, the fixture 300 is designed to allow movementof the plurality of unfused single layers 200 in only two degrees offreedom. In this case, the fixture 300 is designed to allow movement ofthe plurality of unfused single layers 200 in a lengthwise or axialdirection (y-direction). Stated differently, the fixture 300 is designedto restrict movement of the plurality of unfused single layers 200 inthe x- and z-directions.

If any of the unfused single layers 200 are identified as beingdefective during assembly, then the damaged single layer 200 may bediscarded and replaced with another single layer 200 during assembly. Inother words, the unfused single layer 200 or a plurality of unfusedsingle layers 200 may be discarded if damaged. However, an entireunfused segment is not discarded when one or more of the unfused singlelayers 200 are identified as damaged. Accordingly, the manufacturingprocess described herein generates little waste compared to conventionaldownhole tool manufacturing techniques.

According to one example, the fixture 300 may be segmented so thatdifferent portions of segment 180 may be manufactured concurrently. Forexample, if one portion of the segment 180 is inspected by an electricaltechnician and another portion of the same segment 180 is inspected by amechanical technician, then the portion inspected by the electricaltechnician may be constructed separate from the portion inspected by themechanical technician. After each portion is approved, the separateportions may be joined or fused together to form the completed segment180. In this way, the manufacturing process may be expedited byoperating in a parallel fashion rather than a serial fashion. Forexample, in a serial operation one of the electrical technician or themechanical technician would first inspect the device and then the otherof the electrical technician or the mechanical technician would inspectthe same device. The manufacturing process may be expedited by allowingdifferent portions of the segment to be manufactured concurrently.

Alternatively, if one of the components to be embedded within thesegment 180 it out of inventory, then the cavity may be left open andthe remainder of the segment 180 may be completed. Once the component isreturned to inventory, then the component may be inserted into thecomponent cavity and the segment 180 may be fused together. Thus, themanufacturing process may be expedited by allowing certain portions ofthe segment 180 to be fused, while other portions of the segment 180 areleft unfused until the appropriate components are available.

According to one example, the fixture 300 includes alignment featuresthat maintain design tolerances for the segments 180. For example, thealignment features may maintain design tolerances such as angletolerances, profile tolerances, and positional tolerances, or the like.The design tolerances are maintained to precisely form conduits orpassages through the segments 180. With reference to FIG. 4, thealignment features may include the large rod 304 and the small rod 306.These alignment features maintain the angle tolerances, the profiletolerances, and the positional tolerances, among other tolerances, inorder to precisely form conduits or passages through the segments 180.One of ordinary skill in the art will readily appreciate that otheralignment features may be provided at the fixture 300 to maintaindesired design tolerances for the segments 180.

FIG. 5 is a perspective view of a fused segment 180 having a depth tobore diameter ratio greater than 10:1 produced from the manufacturingprocess described herein. According to one example, the fused segment180 may include a depth to bore diameter ratio of 100:1. After theunfused single layers 200 are aligned using the fixture 300 as depictedin FIG. 4, a suitable metal joining process is employed to join theunfused single layers 200 together. For example, electron beam weldingmay be employed to join the unfused single layers 200 together.According to one example, electron beam welding may be used to weldworkpieces that are over 4 inches (100 mm) thick. In one example,electron beam welding may penetrate up to a depth of 2.36 inches (60 mm)during one pass. Electron beam welding offers various benefits such asproducing minimal deformations after welding, allowing precise computernumerical control, and producing good results on workpieces having ahigh depth-width ratio. One of ordinary skill in the art will readilyappreciate that other metal joining processes may be used includinglaser sintering, adhesive bonding, or the like. One of ordinary skill inthe art will readily appreciate that the selection of a metal joiningprocess will depend on several factors including a desired strength ofthe final product, cost, and intended use of the completed fusedsegment. According to one example, the fused segment 180 may be formedfrom any material suitable for and compatible with rotary drilling suchas high strength stainless steel.

According to one example, the segment 180 may be constructed from aplurality of fused layers 181 a-181 n that are fused together using ametal joining process. Prior to performing the metal joining process,the plurality of fused layers 181 a-181 n may be arranged in apreselected order and aligned using the alignment features of fixture300 as depicted in FIG. 4. After the metal joining process is performed,the unfused single layers 200 a-200 n become fused together to form asolid segment 180. Additionally, the apertures defined within theplurality of fused layers 181 a-181 n are fused together to form bores184, 186 that extend axially through the segment 180. As discussedabove, a tube 310 may be inserted into any fluid passages during theassembly process to prevent fluid from leaking out of the fluid passage.

According to another example, the fused segment 180 may be subjected toadditional machining or secondary processes. For example, the fusedsegment 180 may undergo case hardening or application of coatings. Theadditional machining may be provided to form multiple intricatecross-sectional profiles, such as inserts with multiple hydraulic andelectrical pathways. One of ordinary skill in the art will readilyappreciate that selected features may be constructed prior to performingthe metal joining process, while other features may be constructed afterthe metal joining process is performed. For example, a long and narrowpassage running axially through the fused segment 180 may be constructedprior to performing the metal joining process. By contrast, a bore foran oil filled port may be machined after the metal joining process isperformed.

With reference again to FIG. 1A, a drilling fluid (mud) 160 may becirculated through the drilling components in a relatively unrestrictedand unimpeded manner to perform functions such as preventing blow-outand preventing collapse of the wellbore 102. According to one example,the drilling fluid 160 may be circulated during drilling operationsthrough the drill string 112, the drill bit 110, and the annulus 109.According to one example, the bore 184 may extend through the drillstring 112 to the drill bit 110 that includes nozzles that direct a flowof the drilling fluid 160. After passing through the drillingcomponents, the drilling fluid 160 may be circulated to the surface 106,where it passes through a filter (not shown) to remove any drillingdebris, such as cuttings or the like. According to one example, thefilter may include a shale shaker or the like. The filtered drillingfluid 160 may be collected in a tank 162 for re-circulation through thedrilling components. The drilling fluid 160 may be formulated to performother functions, including lubricating the drill bit 110, cooling thedrill bit 110, flushing drilling debris such as rock away from the drillbit 110 and upward to the Earth's surface 106 through the annulus 109formed between the wellbore 102 and the drill string 112, and reducingfriction between the drill string 112 and the wellbore 102, or the like.

FIG. 1A illustrates an exemplary rotary steerable drilling device 111,which also may be referred to as a drilling direction control device orsystem. The rotary drilling device 111 is positioned on the drill string112 with drill bit 110. However, one of skill in the art will recognizethat the positioning of the rotary steerable drilling device 111 on thedrill string 112 and relative to other components on the drill string112 may be modified while remaining within the scope of the presentdisclosure. The rotary steerable drilling device 111 may include arotatable drilling shaft that is coupled or attached to a rotary drillbit 110 and to rotary drill string 112 during the drilling operation.

FIG. 6 is a perspective view of a second example of a single layer 600that when fused with other single layers 600 produces a segment 900 asillustrated in FIG. 9. According to one example, the single layer 600may include a square aperture 602 with rounded corners. While the singlelayer 600 is illustrated to include square aperture 602, one of ordinaryskill in the art will readily appreciate that the single layer 600 mayinclude any number of apertures, any size of apertures, any shape ofaperture, to meet desired design goals.

According to one example, the single layer 600 may be formed using knownmachining techniques such as turning, milling, forging, electricdischarge machining (“EDM”), among other subtractive manufacturingtechniques. For example, the single layer 600 may be formed usingsheet-metal forming or stamping processes. Upon creating the singlelayer 600, additional subtractive manufacturing techniques may be usedto define features within the single layer 600. One of ordinary skill inthe art will readily appreciate that selection of the appropriatetechnique for forming and creating the single layer 600 may be based onfactors such as a desired thickness of the single layer 600, desireddimensions of the single layer 600, desired dimensions of featureswithin the single layer 600, and desired tolerances of dimensions, orthe like.

FIG. 7 is a perspective view of a fixture 700 that may be used toassemble the segment 900 from a plurality of unfused single layers 600illustrated in FIG. 6. The fixture 700 defines a spiral-shaped alignmentfeature. The fixture 700 may be dimensioned to correspond to squareaperture 602.

FIG. 8 is a perspective view of the fixture 700 with the plurality ofunfused single layers 600 a-600 n mounted thereon. As shown, the fixture700 is received by the square apertures 602 of the plurality of unfusedsingle layers 600 a-600 n. According to one example, the fixture 700 isdesigned to allow movement of the plurality of unfused single layers 600a-600 n in only two degrees of freedom. In this case, the fixture 700 isdesigned to allow movement of the plurality of unfused single layers 600a-600 n in a lengthwise or axial direction (y-direction). Stateddifferently, the fixture 700 is designed to restrict movement of theplurality of unfused single layers 600 a-600 n in the x- andz-directions.

If any of the unfused single layers 600 a-600 n are identified as beingdefective during assembly, then the damaged unfused single layer 600 maybe discarded and replaced by another unfused single layer 600 duringassembly. In other words, an unfused single layer 600 or a plurality ofunfused single layers 600 may be discarded if damaged. However, anentire segment 900 is not discarded when one or more of the unfusedsingle layers 600 a-600 n is identified as damaged. Accordingly, themanufacturing process described herein generates little waste comparedto conventional manufacturing techniques.

According to one example, the fixture 700 defines a spiral-shapedalignment feature that maintains design tolerances for the segments. Forexample, the spiral-shaped alignment feature may maintain designtolerances such as the angle tolerances, the profile tolerances, and thepositional tolerances in order to precisely form a conduit or passagethrough the segments. One of ordinary skill in the art will readilyappreciate that the fixture 700 may define other alignment features tomaintain desired design tolerances for the segments.

FIG. 9 is a perspective view of the fused segment 900 having a depth tobore diameter ratio greater than 10:1 produced from the manufacturingprocess described herein. After the unfused single layers 600 a-600 nare aligned using the fixture 700 as depicted in FIG. 8, a suitablemetal joining process is employed to join the single layers 600 a-600 ntogether. As described above, electron beam welding may be employed tojoin together the unfused single layers 600 a-600 n. One of ordinaryskill in the art will readily appreciate that other metal joiningprocesses may be used including laser sintering, adhesive bonding, orthe like. One of ordinary skill in the art will readily appreciate thatthe selection of a metal joining process will depend on several factorsincluding a desired strength of the final product, cost, and intendeduse of the completed fused segment 900. According to one example, thesegment 900 may be formed from any material suitable for and compatiblewith rotary drilling such as high strength stainless steel.

According to one example, the segment 900 may be constructed from aplurality of fused layers 901 a-901 n that are fused together using ametal joining process. Prior to performing the metal joining process,the plurality of unfused layers 600 a-600 n may be arranged in apreselected order and aligned using the alignment feature of fixture 700as depicted in FIG. 8. After the metal joining process is performed, theindividual unfused layers 600 a-600 n become fused together to form asolid segment 900. Additionally, the square aperture defined within theplurality of fused layers 901 a-901 n are fused together to form a bore902 that extends axially through the segment 900. As discussed above, atube 310 may be inserted into any fluid passages during the assemblyprocess to prevent fluid from leaking out of the fluid passage.

According to another example, the constructed fused segment 900 may besubjected to additional machining or secondary processes. For example,the constructed fused segment 900 may undergo case hardening orapplication of coatings. The additional machining may be provided toform multiple intricate cross-sectional profiles, such as inserts withmultiple hydraulic and electrical pathways. One of ordinary skill in theart will readily appreciate that selected features may be constructedprior to performing the metal joining process, while other features maybe constructed after the metal joining process is performed. Forexample, a long and narrow passage running axially through the fusedsegment 900 may be constructed prior to performing the metal joiningprocess. By contrast, a bore for an oil filled port may be machinedafter the metal joining process is performed.

Methods of designing and manufacturing segments include employing acomputer file such as computer aided design (“CAD”) software to define athree-dimensional structure of the segment. The CAD software isprogrammed to slice a segment or downhole tool into a plurality oflayers. According to one example, each of the plurality of layers may beof equal thickness. Alternatively, each of the plurality of layers mayhave different thicknesses. For example, the layer thickness may be lessthan 1 mm; less than 10 mm; less than 100 mm; among other layerthicknesses.

According to one example, a computer algorithm may be employed to selecta layer thickness. The layer thickness may be selected based on acomplexity of internal features associated with the corresponding layer.For example, the layer thickness may be selected based on criteria suchas a number of apertures provided in a layer, an area defined by theaperture openings provided in the layer, a smallest aperture size in alayer being smaller than a preselected size, a largest aperture size ina layer being larger than a preselected size, or the like. Additionally,the layer thickness may be selected based on a type of material used toform the segment, a type of joining process selected, or the like. Oneof ordinary skill in the art will readily appreciate that other criteriamay be used to determine a layer thickness.

According to one example, the CAD software may employ a slicing functionto determine a geometry of the plurality of layers. After the geometryis determined, the plurality of layers may be manufactured using thevarious techniques described herein. The number of layers to bemanufactured will depend on a thickness of each layer and an overalllength of the segment. After the plurality of layers is manufactured, analignment feature is inserted into a corresponding aperture of theplurality of layers in order to stack the plurality of layers on thefixture. As described herein, the fixture is designed to allow movementof the plurality of layers in only two degrees of freedom, such as alengthwise or axial direction (y-direction). After the plurality oflayers is appropriately positioned on the alignment feature and anyinternal components are embedded, then a joining process may beperformed to fuse together the plurality of layers.

FIG. 10 is a flowchart of an example method 1000 according to thepresent disclosure. The method 1000 may be implemented using one or moreof the above described components. For example, the method 1000 may beimplemented using a fixture. The fixture may include an alignmentfeature that restricts movement of the plurality of layers to two orfewer degrees of freedom.

The method 1000 may include obtaining a plurality of layers based on aselected length of the segment, wherein each of the plurality of layersincludes an aperture formed therein (block 1002). For example, fivehundred (500) individual layers may be obtained to form a desiredsegment. The method 1000 may further include receiving the aperture fromeach of the plurality of layers over an alignment feature (block 1004).For example, each of the 500 individual layers may include an aperturethat is inserted over an alignment feature to properly align the 500individual layers relative to each other. The alignment feature may beconfigured as described above. The method 1000 also may includerestricting movement of the plurality of layers to two or fewer degreesof freedom (block 1006). For example, the fixture having the alignmentfeature is designed to allow movement of the 500 individual layers in alengthwise or axial direction (y-direction). Additionally, the methodmay include performing a joining process to join the plurality of layers(block 1008). In this way, the 500 individual layers are fused togetherto form a solidly fused segment.

Numerous examples are provided herein to enhance understanding of thepresent disclosure. A specific set of examples are provided as follows.In a first example, a method is disclosed for assembling a segment of adrill string constructed from a plurality of layers, the method includesobtaining a plurality of layers based on a selected length of thesegment, each of the plurality of layers including an aperture formedtherein; receiving the aperture from each of the plurality of layersover an alignment feature; restricting movement of the plurality oflayers to two or fewer degrees of freedom; and joining the plurality oflayers.

In a second example, there is disclosed herein the method according tothe preceding first example, wherein receiving the aperture formed ineach of the plurality of layers over the alignment feature includesreceiving the plurality of layers in a preselected order.

In a third example, there is disclosed herein the method according toany of the preceding examples first to second, further comprisingremoving at least one layer from the alignment feature upon identifyinga defect in the at least one layer.

In an fourth example, there is disclosed herein the method according toany of the preceding examples first to third, further comprisingreplacing the removed at least one layer with at least one replacementlayer, each of the at least one replacement layers including an aperturethat is received over the alignment feature.

In a fifth example, there is disclosed herein the method according toany of the preceding examples first to fourth, wherein joining theplurality of layers is performed after the at least one replacementlayer is received over the alignment feature.

In a sixth example, there is disclosed herein the method according toany of the preceding examples first to fifth, wherein selected ones ofthe plurality of layers include a cavity aperture provided to form acavity within the downhole tool.

In a seventh example there is disclosed herein the method according toany of the preceding examples first to sixth, wherein the cavityaperture receives a component therein during assembly of the segment.

In an eighth example, there is disclosed herein the method according toany of the preceding examples first to seventh, wherein the plurality oflayers are jointed using at least one of electron beam welding, lasersintering, and adhesive bonding.

In a ninth example, a method is disclosed for assembling a segment of adrill string constructed from a plurality of layers, the method includesobtaining a plurality of layers based on a selected length of thesegment, each of the plurality of layers including an aperture formedtherein; receiving the aperture from each of the plurality of layersover an alignment feature; restricting movement of the plurality oflayers to two or fewer degrees of freedom; removing at least one layerfrom the alignment feature upon identifying a defect in the at least onelayer; replacing the removed at least one layer with at least onereplacement layer, each of the at least one replacement layers includingan aperture that is received over the alignment feature; and joining theplurality of layers and the at least one replacement layer.

In a tenth example, there is disclosed herein the method according tothe ninth example, wherein receiving the aperture formed in each of theplurality of layers over the alignment feature includes receiving theplurality of layers in a preselected order.

In an eleventh example, there is disclosed herein the method accordingto the examples ninth and tenth, wherein selected ones of the pluralityof layers includes a cavity aperture provided to form a cavity withinthe segment.

In a twelfth example, there is disclosed herein the method according tothe examples ninth and eleventh, wherein the cavity aperture receives acomponent therein during assembly of the segment.

In a thirteenth example, there is disclosed herein the method accordingto the examples ninth and twelfth, wherein the component includes atleast one of a sensor, an antenna, and electrical wiring.

In a fourteenth example, a system is provided for forming a segment of adrill string, the system includes a plurality of layers, each of theplurality of layers including an aperture formed therein; an alignmentfeature that receives the plurality of layers, the alignment featurerestricting movement of the plurality of layers to two or fewer degreesof freedom; and a fastener that joins the plurality of layers to form afused segment.

In a fifteenth example, there is disclosed herein the joint according tothe preceding fourteenth example, wherein the alignment feature receivesthe plurality of layers in a preselected order.

In a sixteenth example, there is disclosed herein the joint according tothe preceding fourteenth and fifteenth examples, wherein the alignmentfeature allows removal of at least one layer upon identifying a defectin the at least one layer.

In a seventeenth example, there is disclosed herein the joint accordingto the preceding fourteenth and sixteenth examples, wherein thealignment feature allows replacement of the at least one layer with atleast one replacement layer, each of the at least one replacement layersincluding an aperture that is received over the alignment feature.

In an eighteenth example, there is disclosed herein the joint accordingto the preceding fourteenth and seventeenth examples, wherein thefastener includes at least one of an electron beam welder, a lasersinter, and an adhesive bonder.

In a nineteenth example, there is disclosed herein the joint accordingto the preceding fourteenth and eighteenth examples, wherein selectedones of the plurality of layers include a cavity aperture provided toform a cavity within the segment.

In a twentieth example, there is disclosed herein the joint according tothe preceding fourteenth and nineteenth examples, wherein the cavityaperture receives a component therein.

The embodiments shown and described above are only examples. Even thoughnumerous characteristics and advantages of the present technology havebeen set forth in the foregoing description, together with details ofthe structure and function of the present disclosure, the disclosure isillustrative only, and changes may be made in the detail, especially inmatters of shape, size and arrangement of the parts within theprinciples of the present disclosure to the full extent indicated by thebroad general meaning of the terms used in the attached claims. It willtherefore be appreciated that the embodiments described above may bemodified within the scope of the appended claims.

What is claimed is:
 1. A system for assembling a segment of a drillstring, the system comprising: a plurality of unfused physical layersincluding an aperture formed therein, the plurality of unfused physicallayers manufactured based on a plurality of planned layers, theplurality of planned layers determined by slicing a virtualthree-dimensional tubular structure into the plurality of plannedlayers; an alignment feature having the plurality of unfused physicallayers inserted over the alignment feature to align the aperture formedtherein from the plurality of unfused physical layers, and wherein theplurality of unfused physical layers are fused to form the segment, theaperture of each of the plurality of unfused physical layers togetherforming a common bore.
 2. The system of claim 1, wherein the pluralityof unfused physical layers are fused via electron beam welding.
 3. Thesystem of claim 1, wherein the plurality of unfused physical layers arearranged in a preselected order over the alignment feature.
 4. Thesystem of claim 1, wherein the alignment feature is spiral shaped. 5.The system of claim 1, wherein the alignment feature maintains designtolerances for the segment.
 6. The system of claim 1, wherein thealignment feature comprises parallel rods and each of the plurality ofunfused physical layers includes two or more apertures formed therein toreceive the parallel rods.
 7. The system of claim 6, wherein theparallel rods comprise a large rod and a small rod, the large rod havinga larger diameter than the small rod.
 8. The system of claim 7, furthercomprising fitting an insert over at least one of the large rod or thesmall rod before arranging the plurality of unfused physical layers overthe alignment feature.